Integrated feeder nozzle

ABSTRACT

A system for making a welded assembly. The system may include a welding system that is configured to weld a first part to a second part with a laser beam. The system may further include an integrated feeder nozzle that includes an inlet manifold that receives a shield gas, and a nozzle body secured to the inlet manifold. The nozzle body may include a plurality of peripheral apertures that extend through the conical distal region and that are arranged around a central axis of the nozzle body. The system may further include a wire feeder disposed in the inlet manifold and the nozzle body. The wire feeder receives a welding wire and guides the welding wire to the central aperture.

TECHNICAL FIELD

This disclosure relates to a system and method of making a weldedassembly, and more particularly to a system and method that includes anintegrated feeder nozzle.

BACKGROUND

A method of assembling a crown wheel for a differential gear assembly ofa vehicle is disclosed in U.S. Pat. No. 8,015,899.

SUMMARY

In at least one approach, a system for making a welded assembly isprovided. The system may include a welding system that is configured toweld a first part to a second part with a laser beam. The system mayfurther include an integrated feeder nozzle that includes an inletmanifold that receives a shield gas, and a nozzle body secured to theinlet manifold. The nozzle body may include a conical distal region thatdefines a central aperture that is located at a distal end of the nozzlebody. The nozzle body may further include a plurality of peripheralapertures that extend through the conical distal region and that arearranged around a central axis of the nozzle body. The plurality ofperipheral apertures may direct the shield gas toward the first part andthe second part. The system may further include a wire feeder disposedin the inlet manifold and the nozzle body. The wire feeder may receive awelding wire and guides the welding wire to the central aperture.

In at least one approach, a method of making a welded assembly isprovided. The method may include positioning a first part on a secondpart. The method may further include positioning an integrated feedernozzle adjacent to a weld zone between the first part and the secondpart at which a weld is to be provided. The integrated feeder nozzle mayinclude an inlet manifold and a nozzle body secured to the inletmanifold. The nozzle body may have a conical distal region that definesa central aperture that is located at a distal end of the nozzle body.The nozzle body may further include a plurality of peripheral aperturesthat extend through the conical distal region and are arranged around acentral axis of the nozzle body. The plurality of peripheral aperturesmay direct the shield gas toward the first part and the second part. Theintegrated feeder nozzle may further include a wire feeder disposed inthe inlet manifold and the nozzle body.

The method may further include directing a laser at the weld zone, andproviding a shield gas proximate the weld zone with the peripheralapertures of the integrated feeder nozzle. The method may furtherinclude feeding a welding wire through the wire feeder and through thecentral aperture of the nozzle body.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a system for making a welded assembly.

FIG. 2 is a perspective view of a portion of the system including alaser head.

FIG. 3 is an exploded perspective view of a local delivery system thatmay be provided with the system.

FIG. 4 is a side elevational view of the local delivery system.

FIG. 5 is a perspective view of the laser head including an integratedfeeder nozzle.

FIG. 6 is a cross-sectional view of the integrated feeder nozzle.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

Discrete metal components may be welded together through laser weldingtechniques, such as deep penetration welding. In deep penetrationwelding, a high-power laser, such as a gas laser or a solid-state laser,may be focused on a workpiece. The focal point of the laser beam islocated below the surface of the workpiece. For example, the focal pointmay be located at a depth of approximately 2-3 millimeters below thesurface of the workpiece. In other examples, the focal point may belocated at a depth in the range of approximately 6-10 millimeters belowthe surface of the workpiece. At the focal point, the beam may have abeam width in the range of approximately 200-800 microns. In oneexample, the beam has a beam width of approximately 300 microns at thefocal point. In another example, the beam has a beam width ofapproximately 600 microns at the focal point.

During deep penetration welding, the laser beam melts the metalworkpieces and produces a metallic vapor. The vapor exerts pressure onthe molten metal and partially displaces it, forming a weld pool. Theresult is a deep, narrow, vapor-filled hole, or keyhole, which issurrounded by the molten weld pool. The keyhole and molten weld poolformed by the laser beam may be referred to as the “weld zone.” The weldzone is created by the laser beam as the laser beam advances andprovides a weld joint between the workpieces. The molten metalsolidifies as the weld zone advances, thereby forming the weld betweenthe workpieces.

Referring to FIG. 1, an example of a system 10 for making a weldassembly 12 is shown. The system 10 may include a laser weldingapparatus 14 that may include a multi-axis motion control system, suchas a manipulator or robot 16 having one or more movable arms 18. Therobot 16 may be moveable along a track 20. The laser welding apparatus14 may include a laser head 22 attached to a movable arm 18 of the robot16. The movable arm 18 may be used to position the laser head 22 inrelation to the weld assembly 12.

The system 10 may further include a workstation 24, which may belocated, for example, in a weld cell. The workstation 24 may include aclamping assembly 26 for supporting the components to be welded or weldassembly 12. The clamping assembly 26 may be adapted to both positionand hold the weld assembly 12 during welding. The clamping assembly 26may also be adapted to rotate the weld assembly 12 (for example, about acentral axis of the weld assembly 12) relative to the laser head 22.

The weld assembly 12 may include a first component 28 and a secondcomponent 30. The first component 28 and second component 30 may bedetached prior to welding and may be coupled together with a weld afterwelding. The weld assembly 12 may also include three or more components.

In one example, the first component 28 is a first gear component, suchas a ring gear. The second component 30 may be a second gear component,such as a differential case or housing. In this example, the first andsecond components 28, 30 form a differential assembly. In otherexamples, the weld assembly 12 is a powertrain assembly such as a drivengear assembly, a planetary carrier assembly, a gear shaft assembly, atransmission shaft, or other shaft assembly. In still other examples,the weld assembly 12 is a non-powertrain assembly.

The first component 28 and the second component 30 may be formed ofsimilar or dissimilar materials. In one example, the first component 28may be a ring gear formed of steel. The second component 30 may be adifferential case formed of cast iron. In another example, the firstcomponent 28 and the second component 30 may both be formed of steel. Instill another example, the first component 28 and the second component30 may both be formed of cast iron.

Referring to FIG. 2, a laser head 22 includes an attachment plate 40adapted to secure the laser head 22 to a multi-axis control system, suchas the manipulator or robot 16 of FIG. 1. The laser head 22 furtherincludes a laser input 42 for receiving a laser beam 44 from a laserbeam source or laser beam generator. The laser may be of any suitabletype, such as a gas laser (e.g., CO₂) or a solid-state laser (e.g., aytterbium-doped fiber laser or a Nd:YAG laser). The laser beam 44 may bedirected through a beam projector 46 of the laser head 22. The laserhead 22 may further include one or more lenses or beam-shapingcomponents 48.

The laser head 22 may further include a seam tracking device 50. Theseam tracking device 50 may include a tracking laser projector 52adapted to project a tracking laser 54 onto the weld assembly 12; forexample, at a weld zone between the first and second components 28, 30of the weld assembly 12. The tracking laser projector 52 may include oneor more laser diodes and laser optics (e.g., laser collimators). Theseam tracking device 50 may further include an optical tracking device56, such as a camera. The camera may be disposed at a triangulationangle relative to the tracking laser 54. The seam tracking device 50 maybe used to monitor welding operations performed by the laser head 22.For example, the seam tracking device 50 may be adapted to detect andreport weld seam variations, discontinuities, or other irregularities.

The laser head 22 may further include a local delivery system 60. Thelocal delivery system 60 may include a gas delivery device 62, a shieldgas delivery device 64, and a wire feeder 66.

The gas delivery device 62, which may be referred to as a cross-jethead, may be connected to a first gas source and may deliver a gas at arelatively high airflow speed. For example, the gas delivery device 62may provide gas at a pressure of approximately 80 psi (552 kPa) or more.The gas may be of any suitable type, such as air, nitrogen, argon, orcombinations thereof. For convenience in reference, the term “airflow”may be used to refer to the flow of gas provided by the gas deliverydevice 62 regardless of whether the type of gas employed.

The gas delivery device 62 may be disposed in proximity to the weld zonesuch that the flow of air projected by the gas delivery device 62 formsa high-velocity gas barrier above or adjacent to the weld zone. Forexample, the gas delivery device 62 may be disposed such that the gasbarrier is spaced at least 10 millimeters above the weld zone. In atleast one approach, the gas delivery device 62 forms the gas barrierapproximately 25-30 millimeters above the weld zone. In this way, thegas barrier formed by the gas delivery device 62 may be located suchthat it does not interfere with the weld zone. The gas barrier producedby the gas delivery device 62 may inhibit molten metal that may beexpelled from the weld zone (e.g., in the form of sparks or spatter)from reaching lenses or other components of the laser head 22. The gasbarrier may also clear vapor or smoke from the weld zone. In this way,the laser beam 44 may pass from the laser head 22 to the weld zonesubstantially free from interference.

A collection system may also be provided with the system 10. Thecollection system may be disposed on an opposite side of the weld zonefrom the gas delivery device 62. The collection system may be, forexample, a dust collection system or a filtering device. In this way,particulates swept up by the high-speed gas flow produced by the gasdelivery device 62 may be directed to and collected at the collectionsystem.

The shield gas delivery device 64, which may be referred to as a shieldgas nozzle, may be connected to a second gas source and may deliver agas, such as an inert gas such as argon, helium, or carbon dioxide, tothe weld zone of the weld assembly 12. The shield gas delivery device 64may be disposed proximate or adjacent to the gas delivery device 62. InFIGS. 2-4, the shield gas delivery device 64 may direct the gas at anon-zero angle (e.g., in the range of approximately 10°-45°) relative tothe direction of the high-speed airflow produced by the gas deliverydevice 62. It is also contemplated that the shield gas delivery device64 may direct gas at other angles, including but not limited to parallelto the direction of the high-speed airflow produced by the gas deliverydevice 62.

With reference to FIG. 4, the shield gas delivery device 64 may beoffset (e.g., vertically offset) from the weld zone to accommodate thewire feeder 66. In such approaches, the shield gas delivery device 64may have a distal end 64 a disposed at a non-zero angle (e.g., 15°-45°)relative to a body portion 64 b of the shield gas delivery device 64 todirect the shield gas toward the weld zone.

The shield gas delivery device 64 may provide a controlled atmospherefor the weld zone while the weld zone is in the molten phase. Byproviding a shield gas to the weld zone, the shield gas delivery device64 may reduce the likelihood of unwanted chemical reactions such asoxidation or hydrolysis during welding operations. Such chemicalreactions may cause undesirable welding characteristics, such asporosity in the solidified weld zone.

The wire feeder 66 may also be disposed at a side of the gas deliverydevice 62 opposite the laser beam 44. In at least one approach, the wirefeeder 66 is a cold wire feeder. In another approach, the wire feeder 66is a hot wire feeder adapted to carry electric current. The wire feeder66 may be connected to a wire reel that supplies an electrode wire orwelding wire to the wire feeder 66. The wire feeder 66 may also beconnected to a feeding or transfer mechanism that transfers the weldingwire from the wire reel to the wire feeder 66.

An end of the wire feeder 66 may be adapted to deliver a tip end of thewelding wire to the weld zone. A welding wire may be employed whenwelding dissimilar materials, or when the joint between workpiecesincludes a gap, mismatch, or other irregularity.

In at least at least one approach, such as is shown in FIGS. 1-4, thewire feeder 66 may be disposed adjacent to and may be spaced apart fromthe shield gas delivery device 64. In at least one other approach, suchas is shown in FIGS. 5 and 6, the wire feeder 66 may be disposed in theshield gas delivery device 64.

Referring to FIG. 2, one or more components of the local delivery system60 may be secured to a support assembly 70. The support assembly 70 mayinclude a first support member 72 and a second support member 74. Thesecond support member 74 may be rigidly secured to the first supportmember 72 and may be disposed, for example, in a plane extendinggenerally orthogonal to a central axis 44 a of the laser beam 44. Thesecond support member 74 may include a reduced height region 76 defininga passage through which the laser beam 44 may pass. For example, thereduced height region 76 may be a curved region defining the passagethrough which the laser beam 44 may pass. With reference to FIG. 3, thesecond support member 74 may further include a guide track 78. The guidetrack 78 may extend through the entire thickness of the second supportmember 74 or through less than the entire thickness of the secondsupport member 74. The guide track 78 may be a curved guide track, andmay define a curvature that generally corresponds to a curvature of thereduced height region 76.

The support assembly 70 may further include a positioning block 80. Thepositioning block 80 may be secured to the second support member 74. Forexample, the positioning block 80 may include one or more fasteners 82(e.g., cap head screws, thumb screws, bolts, or knobs) that extend intoor through the guide track 78 of the second support member 74. In thisway, the position of the positioning block 80 relative to the secondsupport member 74 may be adjusted by moving the fasteners 82 ofpositioning block 80 through the guide track 78 of the second supportmember 74. Movement of the positioning block 80 relative to the secondsupport member 74 may serve to rotate one or more of the components ofthe local delivery system 60 about the central axis 44 a of the laserbeam 44.

A third support member 84 may be secured to the positioning block 80.The third support member 84 may be disposed, for example, in a planeextending generally parallel to the central axis 44 a of the laser beam44.

The third support member 84 may define a first guide track 88. In atleast one approach, the first guide track 88 extends through the entirethickness of the third support member 84 or through less than the entirethickness of the third support member 84. The first guide track 88 maybe an elongated guide track and may extend along a length of the thirdsupport member 84.

One or more fasteners 86 of the positioning block 80 may extend into orthrough the first guide track 88 of the third support member 84 tosecure the third support member 84 to the positioning block 80. Thefasteners 86 may be in the form of cap head screws, thumb screws, bolts,knobs, or other fasteners or guides. The fasteners 86 may permit theposition of the third support member 84 to be adjusted relative to thepositioning block 80 (and relative to the second support member 74). Forinstance, an axial position of the third support member 84 may beadjusted. In this way, one or more of the components of the localdelivery system 60 may be positioned along the central axis 44 a of thelaser beam 44.

The third support member 84 may also include a second guide track 90.The second guide track 90 may receive one or more fasteners of the gasdelivery device 62. In this way, an axial position of the gas deliverydevice 62 on the third support member 84 may be adjusted relative to theshield gas delivery device 64, the wire feeder 66, or both.

As shown in FIG. 3, the gas delivery device 62 may include a first bodyportion 92 and a second body portion 94. The second body portion 94 maybe secured to the first body portion 92 by one or more fasteners 96. Thesecond body portion 94 may include one or more elongated adjustmentapertures 98 that may be sized to receive the one or more fasteners 96.The fasteners 96 may be adapted to secure the second body portion 94 tothe first body portion 92, for example, by tightening the fasteners 96.The second body portion 94 may be secured to the first body portion 92in a first axial position (e.g., along an axis parallel to the centralaxis 44 a of the laser beam 44) relative to the first body portion 92.The fasteners 96 may also be adapted to permit the second body portionto move to a second axial position relative to the first body portion92. For example, loosening or removing the fasteners 96 may permit thesecond body portion 94 to axially slide in the upstream or downstreamdirection. The fasteners 96 may then secure the second body portion 94to the first body portion 92 in the second axial position, for example,by tightening the fasteners 96. In this way, the second body portion 94may be axially adjustable relative to the first body portion 92.

In at least at least one approach, the first body portion 92 and thesecond body portion 94 may be integrally formed such that the gasdelivery device 62 has a unitary or one-piece construction.

When assembled, the first body portion 92 and the second body portion 94may cooperate to define an interior cavity 100 or plenum of the gasdelivery device 62. A gas interface 102 may be secured at a first end toa conduit connected to a gas source and may be secured at a second endto the gas delivery device 62 (e.g., at the first body portion 92). Thegas interface 102 may be in fluid communication with the interior cavity100 of the gas delivery device 62 to provide gas from the gas source tothe interior cavity 100.

The gas delivery device 62 may also include a bottom plate 104, a topplate 106, a side plate 108, or combinations thereof. The bottom, top,and side plates 104, 106, 108 may be removably coupled to the gasdelivery device 62. In this way, the bottom, top, and side plates 104,106, 108, which may be subjected to high heat and spatter expelled fromthe weld zone, may be replaced over time.

The bottom, top, and side plates 104, 106, 108 may be made of the samematerial or a different material as the first body portion 92. Forexample, the first body portion 92 may be formed of aluminum, and one ormore of the bottom, top, and side plates 104, 106, 108 may be formed ofsteel. In this way, the first body portion 92 may be formed of arelatively lightweight material that is suitable for machining, whilesteel bottom, top, and side plates 104, 106, 108 may protect the firstbody portion 92 from spatter expelled from the weld zone. In still otherapproaches, one or more of the bottom, top, and side plates 104, 106,108 may be coated with a heat-resistant material.

Referring to FIG. 4, the first body portion 92 may include a wall 110that may extend in a plane substantially orthogonal to the central axis44 a of the laser beam 44. The second body portion 94 may similarlyinclude a wall 112 that may extend in a plane substantially orthogonalto the central axis 44 a of the laser beam 44. In this way, the walls110, 112 may be referred to as transverse walls 110, 112. The transversewall 112 of the second body portion 94 may extend, for example, 5millimeters from the second body portion 94.

The transverse walls 110, 112 may include inner surfaces 110 a, 112 afor directing an airflow. The inner surfaces 110 a, 112 a may bedisposed in parallel, or substantially parallel, spaced apart planesthat extend substantially orthogonal to a gas input flow direction atthe gas interface 102.

In at least at least one approach, the transverse walls 110, 112 of thefirst and second body portions 92, 94 may include respective beampassage channels 114, 116. In the assembled configuration, the beampassage channels 114, 116 of the transverse walls 110, 112 of the firstand second body portions 92, 94 may be substantially aligned. Duringwelding operations, the transverse walls 110, 112 may be disposed suchthat the beam passage channels 114, 116 are positioned along a centralaxis of the laser beam 44 such that the laser beam 44 passes through thechannels 114, 116. In some approaches, side plate 108 may also define abeam passage channel that may also be aligned with beam passage channels114, 116 to permit passage of the laser beam 44 therethrough.

Referring to FIG. 4, inner surfaces 110 a, 112 a of the transverse walls110, 112 may define sidewalls of an airflow channel, such as dischargeslot 120. The discharge slot 120 may be an elongated slot (or slit)having a height substantially greater than a width of the elongatedslot. For example, the discharge slot 120 may form a generallyrectangular discharge slot 120. As shown, the bottom plate 104 and thetop plate 106 may define bottom and top walls, respectively, of thedischarge slot 120.

Due at least in part to the orientation of the inner surfaces of thetransverse walls 110, 112 relative to the interior cavity 100, the gasdelivery device 62 may cause the airflow to “bend” or change direction.For example, the airflow may bend or change direction by approximately90 degrees after exiting the gas interface 102, after reaching thesecond body portion 94, and/or when being directed to the discharge slot120. In this way, the transverse walls 110, 112 may cause the airflow toexit through the discharge slot 120 along a plane extending at an anglerelative to a central axis of the laser beam. The discharge slot 120 maydirect airflow in a plane substantially orthogonal to the central axisof the laser beam.

The discharge slot 120 may be disposed such that the airflow is directedover the weld zone of the weld assembly 12 at a height, for example, ofapproximately 25-30 millimeters above the weld zone. In this way, thegas delivery device 62 may form an airflow barrier over the weld zonewithout interfering with the keyhole or molten weld pool of the weldzone.

The transverse walls 110, 112 may define the height of the dischargeslot 120. In at least one approach, the discharge slot 120 may extendalong substantially the entire height of the transverse walls 110, 112.For example, the discharge slot 120 may extend from top portion of thetransverse walls 110, 112 (e.g., from the top plate 106), through thebeam passage channels 114, 116, and to bottom portions of the transversewalls 110, 112 (e.g., to the bottom plate 104). In this way, thetransverse walls 110, 112 may define a discharge slot 120 in the form ofa continuous slot.

In at least one approach, the height of the discharge slot is in therange of approximately 20 millimeters and 100 millimeters, and moreparticularly, in the range of approximately 40 millimeters and 60millimeters. For example, the height of the discharge slot 120 may beapproximately 50 millimeters. Increasing the height of the airflow may,for example, increase the height of the airflow barrier flowing abovethe weld zone. As compared to gas delivery devices having heights ofapproximately 5 to 10 millimeters, the larger airflow barrier propelledthrough the discharge slot 120 of the gas delivery device 62 may reduceor eliminate “edge effects” above the weld zone.

A larger airflow barrier may also form a “blanket” layer above theshield gas provided by the shield gas delivery device 64. This blanketlayer may inhibit dissipation of the shield gas away from the weld zoneof the weld assembly 12, thereby maintaining the controlled atmosphereprovided by the shield gas at the weld zone. Furthermore, by stabilizingthe shield gas layer, the blanket layer may permit a user to adjust oneor more parameters of the shield gas delivery system. For example, auser may reduce the velocity of the shield gas exiting the shield gasdelivery device 64. Reducing the velocity of the shield gas across theweld zone may reduce the likelihood of the shield gas disrupting theweld pool, and may further reduce the likelihood of molten spatterejection from the weld zone.

The transverse walls 110, 112 may also define the width of the dischargeslot 120. The width of the discharge slot 120 may extend between innersurfaces 110 a, 112 a of the transverse walls 110, 112 in a directiongenerally orthogonal to the height of the discharge slot 120 (e.g.,parallel to the central axis 44 a of the laser beam 44.

In at least one approach, the width of the discharge slot is in therange of approximately 0.2 millimeters and 3 millimeters. For example,the width of the discharge slot 120 may be in the range of approximately0.5 millimeters to 1 millimeter. In this way, the discharge slot 120 mayhave a height in the range of approximately 10 to 100 times, and moreparticularly, 40 to 60 times greater than the width of the dischargeslot. In one example, the discharge slot 120 has a height ofapproximately 50 millimeters and a width of approximately 1 millimeter,thus having a height-to-width ratio of approximately 50:1. In anotherexample, the discharge slot 120 has a height of approximately 50millimeters and a width of approximately 0.5 millimeters, thus having aheight-to-width ratio of approximately 100:1.

In at least one approach, the width of the discharge slot 120 may beconstant along an entire height of the discharge slot 120. In anotherapproach, the width of the discharge slot 120 may vary along the heightof the discharge slot 120.

The width of the discharge slot 120 may be controlled by adjusting thesecond body portion 94 relative to the first body portion 92. Forexample, the elongated adjustment apertures 98 may permit a user toslide the second body portion 94 axially relative to the first bodyportion 92 from a first position defining a first distance between thetransverse walls 110, 112 of the first and second body portions 92, 94to a second position defining a second distance between the transversewalls 110, 112 of the first and second body portions 92, 94. Reducingthe width of the discharge slot 120 may increase airflow velocity.Increasing the velocity of the airflow may provide an “air-knife” orair-knife effect capable of clearing spatter and other debris away fromthe weld zone.

The discharge slot 120 may configured to provide laminar airflow orsubstantially laminar airflow. Laminar flow may be defined as streamlineflow of a fluid in which the direction of flow at every point remainsconstant or in which all particles of the fluid move in distinct andseparate lines. Laminar airflow may be free of swirls or eddies at acentral axis of the laminar flow as the laminar airflow flows over theweld zone. Substantially laminar airflow may be substantially free ofswirls or eddies at a central axis of the substantially laminar flow asthe substantially laminar airflow flows over the weld zone. The centralaxis of the laminar or substantially laminar flow may be located atapproximately half of the height of the discharge slot 120.

Laminar flow may be contrasted with turbulent flow, which may beproduced by devices having circular or elliptical cross-sectionalprofiles. Turbulent airflow may be substantially comprised of swirls oreddies at a central axis of the turbulent flow as the turbulent airflowflows over the weld zone. In this way, as compared to a turbulentairflow, the laminar airflow may provide a more consistent andpredictable airflow pattern above the weld zone.

The shield gas delivery device 64 and the wire feeder 66 may be discreteunits secured within the local delivery system 60.

Referring to FIGS. 5 and 6, the wire feeder and the shield gas deviceform an integrated feed nozzle 130.

The integrated feed nozzle 130 may include an inlet manifold 132defining an interior cavity 134. The inlet manifold 132 may be formed,for example, of copper, aluminum, steel, or other suitable material.

The inlet manifold 132 may include a shield gas inlet 136 disposedthrough a wall of the inlet manifold 132. The shield gas inlet 136 maybe formed in a side wall of the inlet manifold 132. As such, the shieldgas inlet 136 may have a central axis disposed at an angle generallyorthogonal to a central axis of the inlet manifold 132.

The shield gas inlet 136 may be sized to receive a first end of aconduit. A second, opposite end of the conduit may be secured a shieldgas source that contains, for example, an inert gas such as argon,helium, or carbon dioxide. In this way, gas supplied by the shield gassource may be in fluid communication with the interior cavity 134 of theinlet manifold 132. Gas flow may be regulated by a pressure regulator.

The integrated feed nozzle 130 may also include a nozzle body 140. Thenozzle body 140 may also be referred to as a gas diffuser. The nozzlebody 140 may define a proximal region 140 a having a substantiallyconstant diameter and a conical distal region 140 b. The conical distalregion 140 b may define a conically-tapered wall that progressivelytapers from the proximal region 140 a a central axis of the nozzle body140.

The nozzle body 140 may be secured to the inlet manifold 132. Forinstance, a proximal region 140 a of the nozzle body 140 is disposed ina coaxial configuration relative to the inlet manifold 132.

The nozzle body 140 may be susceptible to high wear. Thus, the nozzlebody 140 may be configured to be replaced. In at least one approach, theouter surface of the proximal region 140 a of the nozzle body 140 mayinclude one or more threads for threadedly engaging correspondingthreads on the interior surface of the end portion of the inlet manifold132. In another approach, the proximal region 140 a may be press-fitinto the end portion of the inlet manifold 132. In these exemplaryapproaches, the proximal region 140 a of the nozzle body 140 may bepartially disposed within the interior cavity 134 of the inlet manifold132. In still other approaches, the interior surface of the proximalregion 140 a may engage an exterior surface of the end portion of theinlet manifold 132 such that the inlet manifold 132 is received withinthe proximal region 140 a of the nozzle body 140.

The nozzle body 140 may be a hollow nozzle body defining an interiorchannel 142. The interior channel 142 of the nozzle body 140 may befluid communication with the interior cavity 134 of the inlet manifold.In this way, gas supplied by the shield gas source to the interiorcavity 134 of the inlet manifold 132 may flow into the interior channel142 of the nozzle body 140.

The nozzle body 140 may be formed of a material having a high thermalconductivity. In at least one approach, the nozzle body 140 may beformed of a metal or metal alloy.

The nozzle body 140 includes one or more peripheral apertures 144 thatmay extend through the nozzle body 140. For example, the nozzle body 140may include eight peripheral apertures 144 radially spaced about thecentral axis of the nozzle body 140. The peripheral apertures 144 may bein the form of conical apertures, cylindrical apertures, elongatedslits, or may have any other suitable geometry. In at least oneapproach, such as is shown in FIG. 6, central axes of the peripheralapertures 144 may extend at non-zero angles (e.g., in the range ofapproximately 10°-45°) relative to the central axis of the nozzle body140. It is also contemplated that central axes of the peripheralapertures 144 may extend at other angles, such as parallel to thecentral axis of the nozzle body 140.

The peripheral apertures 144 may be formed through a conical distalregion 140 b of the nozzle body 140. Shield gas flowing through theinterior channel 142 of the nozzle body 140 may be expelled through theperipheral apertures 144 in the direction of the weld zone of a weldassembly 12. The shield gas may be delivered at a rate in the range ofapproximately 25-45 cubic feet per hour (cfh) (0.56-1.13 cubic metersper hour).

The nozzle body 140 may also include a central aperture 146 that mayextend through a distal end of the conical distal region 140 b of thenozzle body 140. The central aperture 146 may be disposed about (e.g.,may be coaxial with) the central axis of the nozzle body 140, and may belocated at the distal end of the integrated feed nozzle 130. The centralaperture 146 may have a diameter in the range of approximately 0.5-1.0millimeters.

The distal end of the nozzle body 140 may define the distal end of theintegrated feed nozzle 130 (i.e., the furthest end axially downstream).As such, an outer surface of the conical distal region 140 b of thenozzle body 140 forms the outermost surface of the distal end of theintegrated feed nozzle 130. In this way, the outermost surface of thedistal end of the integrated feed nozzle 130 may define a plurality ofapertures (i.e., the one or more peripheral apertures 144 and thecentral aperture 146).

The integrated feed nozzle 130 may also include a wire feeder 150. Thewire feeder 150, which may also be referred to as a liner, may extendthrough the interior cavity 134 of the inlet manifold 132 and throughthe interior channel 142 of the nozzle body 140. For example, the wirefeeder 150 may be coaxially disposed with the inlet manifold 132 and thenozzle body 140.

Outer surfaces of the wire feeder 150 may be spaced from inner surfacesof the nozzle body 140 such that at least a portion of the interiorchannel 142 of the nozzle body 140 may be substantially empty. In thisway, shield gas may be communicated through the empty portion of theinterior channel 142 of the nozzle body 140.

In at least one approach, a distal end region 150 a of the wire feeder150 may engage the inner surface of the conical distal region 140 b ofthe nozzle body 140. For instance, the entire circumferential peripheryof the distal end region 150 a of the wire feeder 150 may engage theinner surface of the conical distal region 140 b of the nozzle body 140.As such, the distal end region 150 a of the wire feeder 150 may form afluid-tight seal with the inner surface of the conical distal region 140b of the nozzle body 140. The fluid-tight seal may be disposed axiallybetween the peripheral apertures 144 and the central aperture 146. Inthis way, shield gas flowing through the interior channel 142 of thenozzle body 140 may be restricted from reaching the central aperture146. In this way, shield gas flowing through the nozzle body 140 isdirected through the peripheral apertures 144 and is substantiallyinhibited from flowing upstream through the wire feeder 150.

The wire feeder 150 may be a hollow nozzle body defining an interiorchannel 152. A welding wire 154 may be fed through the interior channel152 of the wire feeder 150. The welding wire 154 is preferablymetallurgically compatible with the base materials being joined. Thewire material may be an alloy having a relatively high composition (byweight) of nickel, chromium, or nickel and chromium. The welding wire154 may have a diameter in the range of 0.25 and 10 millimeters, andmore particularly, in the range of 0.9 and 1.5 millimeters. The weldingwire 154 may have a tip region 154 a adapted to protrude beyond thecentral aperture 146 formed through the conical distal region 140 b ofthe nozzle body 140. In this way, the shield gas and welding wire 154may exit the interior channel 142 of the nozzle body 140 throughdifferent apertures.

During welding operations, the tip region 154 a of the welding wire 154may be disposed adjacent a weld zone of a weld assembly 12. Also duringwelding operations, the laser beam provides sufficient energy to meltthe welding wire 154 proximate the weld zone.

As compared to a configuration having separate gas delivery and wirefeeding components, the integrated feed nozzle 130 may be a relativelycompact local delivery system. For example, proximal region 140 a of thenozzle body 140 may have an outer diameter in the range of approximately6-10 millimeters. The conically-tapered region 140 b of the nozzle body140 may taper from the proximal region 140 a to a distal end having anouter diameter of approximately 5 millimeters. Due at least in part tothis reduced profile, the integrated feed nozzle 130 may be positionedin tight locations between two workpieces to deliver the shield gas inclose proximity to the weld zone. For example, during weldingoperations, the shield gas may be expelled through peripheral apertures144 at a height of approximately 12 millimeters to approximately 20millimeters above the weld zone. The compact configuration of theintegrated feed nozzle 130 may also allow the integrated feed nozzle 130to access weld zones that would not be accessible (or as easilyaccessible) using a local delivery systems having discrete gas deliveryand wire feeding components.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the invention. Rather,the words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.Additionally, the features of various implementing embodiments may becombined to form further embodiments of the invention.

What is claimed is:
 1. A system for making a welded assembly, the systemcomprising: a welding system that is configured to weld a first part toa second part with a laser beam; and an integrated feeder nozzle thatextends along a central axis and includes: an inlet manifold thatreceives a shield gas; a nozzle body secured to the inlet manifold, thenozzle body including: a conical distal region that defines a centralaperture that is located at a distal end of the nozzle body, wherein theconical distal region has an inner surface that faces toward the centralaxis and that extends from the central aperture such a diameter of theinner surface decreases in an axial direction that extends toward thecentral aperture, and a plurality of peripheral apertures that extendfrom the inner surface through the conical distal region and arearranged around the central axis, wherein the plurality of peripheralapertures direct the shield gas toward the first part and the secondpart; and a wire feeder disposed in the inlet manifold and the nozzlebody, wherein the wire feeder receives a welding wire and guides thewelding wire to the central aperture and the wire feeder only contactsthe nozzle body at the distal end of the wire feeder such that thedistal end of the wire feeder contacts the inner surface of the conicaldistal region.
 2. The system of claim 1 wherein the plurality ofperipheral apertures are disposed outside of the wire feeder.
 3. Thesystem of claim 1 wherein the nozzle body has a proximal region disposedbetween the inlet manifold and the conical distal region, wherein theconical distal region has a conically-tapered wall that extends from aproximal region and becomes progressively closer to the central axis ina direction that extends toward the distal end.
 4. The system of claim 3wherein the conically-tapered wall has an outer diameter of 5millimeters at the distal end.
 5. The system of claim 3 wherein thenozzle body has a first end disposed opposite the conical distal endregion, wherein the first end extends to a shield gas inlet of the inletmanifold that receives the shield gas.
 6. The system of claim 1 whereinthe distal end of the wire feeder engages the inner surface between thecentral aperture and the plurality of peripheral apertures.
 7. Thesystem of claim 1 wherein engagement of the distal end of the wirefeeder and the inner surface forms a fluid-tight seal that inhibits theshield gas from entering the central aperture.
 8. The system of claim 1wherein the distal end of the wire feeder is disposed closer to thedistal end of the nozzle body than the plurality of peripheral aperturesare disposed to the distal end of the nozzle body.
 9. The system ofclaim 1 wherein the plurality of peripheral apertures is disposed at anon-zero angle with respect to the central axis.
 10. The system of claim9 wherein the plurality of peripheral apertures is disposed at an anglein a range of between 10 degrees to 45 degrees relative to the centralaxis.
 11. The system of claim 1 wherein the nozzle body extends into aninterior cavity of the inlet manifold.
 12. The system of claim 1 whereinthe inlet manifold includes a shield gas inlet formed in a side wall ofthe inlet manifold.
 13. The system of claim 12 wherein a central axis ofthe shield gas inlet is disposed generally orthogonal to the centralaxis.
 14. The system of claim 13 wherein the shield gas inlet providesshield gas to the inlet manifold and a region of the nozzle bodydisposed outside the wire feeder.
 15. The system of claim 1 wherein theinlet manifold is made of steel and the nozzle body is made of copper.16. The system of claim 1 further comprising a gas delivery device thatprovides a pressurized gas toward the laser beam, the gas deliverydevice being disposed between the integrated feeder nozzle and the laserbeam.
 17. The system of claim 16 wherein the gas delivery device ismovable relative to the integrated feeder nozzle in a direction parallelto a path of the laser beam.
 18. A method of making a welded assembly,the method comprising: positioning a first part on a second part;positioning an integrated feeder nozzle adjacent to a weld zone betweenthe first part and the second part at which a weld is to be provided,the integrated feeder nozzle including: an inlet manifold; a nozzle bodysecured to the inlet manifold, the nozzle body having a conical distalregion that defines a central aperture that is located at a distal endof the nozzle body, and a plurality of peripheral apertures that extendfrom an inner surface of the conical distal region through the conicaldistal region and are arranged around a central axis of the nozzle body,wherein the plurality of peripheral apertures direct a shield gas towardthe first part and the second part; and a wire feeder disposed in theinlet manifold and the nozzle body; directing a laser at the weld zone;providing a shield gas proximate the weld zone with the peripheralapertures of the integrated feeder nozzle; and feeding a welding wirethrough the wire feeder and through the central aperture of the nozzlebody, wherein the inner surface of the conical distal region facestoward the welding wire and extends from the central aperture such adiameter of the inner surface decreases in an axial direction thatextends toward the central aperture and the wire feeder only contactsthe nozzle body at the distal end of the wire feeder such that thedistal end of the wire feeder contacts the inner surface of the conicaldistal region.
 19. The method of claim 18 wherein the distal end of thewire feeder is disposed closer to the distal end of the nozzle body thanthe plurality of peripheral apertures are disposed to the distal end ofthe nozzle body.
 20. The method of claim 18 further comprising providinga gas that inhibits molten metal from being expelled from the weld zonewith a gas delivery device, wherein the gas delivery device ispositioned closer to a laser welding apparatus than the integratedfeeder nozzle.